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The Genie S-60 articulating boom lift is renowned for its versatility and reliability in various industrial applications. However, operators occasionally encounter issues with the drive and steer joysticks, leading to operational challenges. This article delves into common problems associated with these joysticks, diagnostic procedures, and potential solutions.
Understanding the Joystick System
The drive and steer functions in the Genie S-60 are controlled via dual-axis joysticks equipped with Hall Effect sensors. These sensors detect the joystick's position and send corresponding signals to the ALC-500 control board, which interprets the inputs to control the machine's movements.
Common Issues
- Non-Responsive Joysticks: Operators may find that the drive and steer joysticks do not respond to inputs, rendering the machine immobile.
- Erratic Movements: Joysticks might cause unpredictable movements, such as sudden jerks or unintended directions.
- Calibration Failures: Attempting to calibrate the joysticks may result in no audible confirmation (beep), indicating a failure in the calibration process.
- Check for Error Codes: The ALC-500 control board displays error codes through LED indicators. For joystick-related issues, common codes include:
- 51-17: Drive joystick malfunction.
- 61-17: Steer joystick malfunction.
- 51-17: Drive joystick malfunction.
- Inspect Voltage Signals: Using a multimeter, measure the voltage output from the joystick connectors. A properly functioning joystick should produce a voltage range from 0V to 5V as it is moved through its range. A consistent 2.5V reading across all directions may indicate a faulty joystick.
- Perform Joystick Calibration:
- Turn the key switch to the "Platform" position.
- Pull out the emergency stop button.
- Remove the joystick from its connector.
- Wait for 3-4 seconds, then reconnect the joystick.
- Without stepping on the foot switch, move the joystick fully in each direction and hold for 5-7 seconds.
- If calibration is successful, an audible beep will confirm the process.
- Turn the key switch to the "Platform" position.
- Joystick Replacement: If the joystick fails to produce the correct voltage signals or calibration is unsuccessful, replacing the joystick may be necessary. Ensure that the replacement part is compatible with the S-60 model.
- Control Board Inspection: Persistent issues after joystick replacement may point to problems with the ALC-500 control board. Inspect the board for visible damage or loose connections. In some cases, reprogramming or replacing the board may be required.
- Wiring and Connector Checks: Inspect all wiring and connectors between the joystick and the control board for signs of wear, corrosion, or loose connections. Repair or replace as needed.
An operator reported encountering error codes 51-17 and 61-17 on their 2006 Genie S-60. After verifying the joystick's voltage signals and attempting calibration without success, the operator replaced the joystick. This action resolved the issue, restoring full functionality to the drive and steer controls.
Conclusion
Issues with the drive and steer joysticks in the Genie S-60 can stem from various sources, including faulty joysticks, control board malfunctions, and wiring problems. By systematically diagnosing the issue using the procedures outlined above, operators can identify the root cause and implement the appropriate solution, ensuring the continued reliability and safety of the equipment.
